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Old 29th July 2012, 08:34 PM   #11
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Click the image to open in full size.

Note Caddocks MK132 orientation.

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Note that R13 can be completely soldered from start even if one lead goes to ground since the bottom pad it's not directly connected to the groundplane.

R104/R204 ground leads are not soldered since on thermals.

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Attached Images
File Type: jpg 36 R13 orientation.jpg (188.2 KB, 2048 views)
File Type: jpg 37 Caddocks soldering.jpg (166.7 KB, 2037 views)
File Type: jpg 38 Caddocks soldered.jpg (217.4 KB, 1187 views)
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Old 29th July 2012, 08:43 PM   #12
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As it could be noted all markings on boards are oriented so that marked parts could be easily oriented.

See for FKP2s

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FKP2s orientation

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Click the image to open in full size.

Then solder C10

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Attached Images
File Type: jpg 39 FKP2 orientation.jpg (140.5 KB, 1161 views)
File Type: jpg 40 filter FKP2.jpg (173.4 KB, 1165 views)
File Type: jpg 41 Wima bypasses.jpg (186.3 KB, 1154 views)
File Type: jpg 42 C10.jpg (114.3 KB, 1155 views)
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Old 29th July 2012, 08:54 PM   #13
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Now it's the turn of connectors.

There are two types of Molex included in BOM tin plated (EXT LED) and gold plated (IN)

Click the image to open in full size.

Then put in place faston tabs and solder on the upper side one end

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Click the image to open in full size.

To obtain this result tabs must be heated with the soldering iron to be soldered

Then reverse board and solder all the tabs:

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Attached Images
File Type: jpg 43 molex.jpg (188.3 KB, 1153 views)
File Type: jpg 44 Apply solder.jpg (120.6 KB, 1148 views)
File Type: jpg 45 result.jpg (127.5 KB, 1147 views)
File Type: jpg 46 solder underside.jpg (135.1 KB, 1146 views)
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Old 30th July 2012, 12:53 PM   #14
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A further note on faston tabs.

If the soldering temperature it's not enough to obtain results depicted in previous post defer their installation to when we'll raise soldering temperature to solder thermal pads.

Back on topic.

Now we solder C1 and C2:

Click the image to open in full size.

Click the image to open in full size.

As usual we'll leave thermal pads for later (we'll raise soldering temperature to solder all of them)

It's LM317s turn

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Now MP915s

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Note that ceramic pads side goes on the outside for both.
Attached Images
File Type: jpg 47 C1 and C2.jpg (175.7 KB, 1124 views)
File Type: jpg 48 C1 and C2 pads.jpg (130.6 KB, 1119 views)
File Type: jpg 49 LM317s.jpg (192.0 KB, 1114 views)
File Type: jpg 50 MP915s.jpg (192.9 KB, 1120 views)
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Old 30th July 2012, 01:01 PM   #15
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Now an essential component that could be easily forgot resulting in a not working amp or worse...

The unique jumper in the whole board (J1) which carries V-

Using pliers make a 12mm jumper:

Click the image to open in full size.

If you bought Rikens you can use their gold plated leads after trimming.

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Click the image to open in full size.

Note that J1 jumper is installed in the bottom side and soldered on the upper side.
Attached Images
File Type: jpg 51 J1.jpg (98.7 KB, 1116 views)
File Type: jpg 52 J1 in place.jpg (134.7 KB, 1125 views)
File Type: jpg 52 j1 pads.jpg (190.7 KB, 1118 views)
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Old 30th July 2012, 01:44 PM   #16
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Now it's rectifiers diodes turn

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As usual thermal pads are left unsoldered.

Proceed soldering the relay, start from one or two pads while keeping it in place with fingers

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Proceed with other pads leaving out the thermal one.

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Attached Images
File Type: jpg 53 MUR820s.jpg (186.2 KB, 1116 views)
File Type: jpg 54 MUR820s pads.jpg (126.3 KB, 1113 views)
File Type: jpg 55 relay first pad.jpg (137.9 KB, 1114 views)
File Type: jpg 56 relay pads.jpg (134.7 KB, 1201 views)
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Old 30th July 2012, 02:01 PM   #17
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Prepare R3s with thermal compound (a thin layer)

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And fix them to heatsinks using M3 screws and bolts

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M3 screws and bolts are not indicated in BOM but can be easily sourced from any hardware store. Prefer non magnetic materials like brass.

Solder R3 in place.

Now it's time to raise soldering iron temperature (min 350C), solder all thermal pads we left in previous steps and trim remaining leads.

Click the image to open in full size.

Note that in the previous picture I forgot to solder relay's pad...
Attached Images
File Type: jpg 57 R3 compound.jpg (94.2 KB, 1123 views)
File Type: jpg 58 R3 prepared.jpg (102.2 KB, 1094 views)
File Type: jpg 59 soldered thermals.jpg (186.9 KB, 1098 views)
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Old 30th July 2012, 02:32 PM   #18
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To solder LM3886TF take measures and drill heatsinks then fix the opamp to heatsinks

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Then insert LM3886, together the heatsink, in place on board and solder a pair of pins on the upperside to keep chip in place.

Unmount opamp from heatsink, reverse board and solder all pins.

The nearly ready boards

Click the image to open in full size.

Click the image to open in full size.

The only remaining components, not covered here are the big smoothing caps and imput cap.
Attached Images
File Type: jpg 60 LM3886 on hs.jpg (145.3 KB, 1132 views)
File Type: jpg 61 nearly finished board 1.jpg (215.4 KB, 1099 views)
File Type: jpg 62 nearly finished board 2.jpg (211.8 KB, 1103 views)
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Old 30th July 2012, 02:51 PM   #19
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Default 3 - Tranformers

As specced each module need a dedicated transformer to avoid hum problems.

Transformers must have double secondaries (2x25V, 2x24 also fine) and 160VA minimum rating (120VA minimum for the more efficient R-Cores).

You must find the label on transformer or its datasheet to wire them.

Selectronic R-Cores

Click the image to open in full size.

With this type of label the first color in the couple is usually hot/phase, the second neutral.

So:

AC1 Violet
NAC1 Gray
AC2 Blue
NAC2 Red

Antek AN-2225

From manifacturer datasheet:

Click the image to open in full size.

With this type of label/wiring you can't distiguish visually each secondary from the other.

One way to do it is using a multimeter to measure continuity.

Members of the same couple will have continuity.

After you identified couples wire in this way:

AC1 Green1
NAC1 Blue 1
AC2 Green 2
NAC2 Blue 2
Attached Images
File Type: jpg 63 R-core.jpg (104.5 KB, 1114 views)
File Type: jpg 64 Antek AN-2225.jpg (30.0 KB, 1108 views)
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Old 30th July 2012, 02:59 PM   #20
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Default Input connector

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I think I've covered most of the build process, If further info is required, please, ask...
Attached Images
File Type: jpg 65 IN.jpg (19.8 KB, 1094 views)
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